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YASKAWA MPL300-J00, Operating And Maintenance Manual

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YASKAWA MPL300-J00 Operating And Maintenance Manual Download Page 89

Parts lists

11

 - 

89

11.5

Balancer unit

Fig. 11-6: Balancer unit

No.

DWG no.

Description

Pcs

5001

HW0481740-A

Spring

1

5002

HW0481741-A

Spring

1

5003

SOB607440

Sleeve

2

5004

HW0100477-1

Housing

1

5005

HW0306033-1

Flange

1

5001

5002

5017

5003

5004

5005

5006

5007

5008

5009

5010

5011

5012

5012

5013

5014

5015

5016

5003

5018

5019

5020

Summary of Contents for MPL300-J00

Page 1: ...ROBOTICS MPL300 J00 YR MPL0300 J00 Operating and Maintenance Manual ...

Page 2: ... However the information given in this publication is checked regularly and any necessary corrections will be made in subsequent editions Subject to technical modifications Created on 2016 08 Revision 04 Document number E1101000217GB04 Author WOE Changes made in revision Rev 01 Revised version of the original HW1482991 0 in YEU R style 2015 05 Rev 02 Revised version of the original HW1482991 1 201...

Page 3: ...easures 17 4 2 Ambient conditions and installation location 18 4 3 Installation example 18 5 Wiring 21 5 1 Grounding 21 5 2 Cable connections 22 5 2 1 Connecting the robot 23 5 2 2 Connection of the robot controller 24 5 2 3 Connecting the programming pendant 25 6 Technical data 26 6 1 Parts and work axis label 27 6 2 Robot base dimension 27 6 3 Dimensions and defined working area 28 6 4 Adjustabl...

Page 4: ...he main axes 60 9 3 2 Grease replenishment exchange the wrist axes 62 9 3 3 Refilling the amount of grease in joints 63 9 4 Home position calibration 64 9 4 1 Register all axes 65 9 4 2 Register individual axes 68 9 4 3 Changing absolute data 69 9 4 4 Clearing absolute data 70 9 5 Setting the second home position check point 71 9 5 1 Purpose of position check operation 71 9 5 2 Procedure for the s...

Page 5: ...s NOTICE Indicates important background information and application advice 1 2 Frequently used terms The YASKAWA robot is a product of YASKAWA Electric Corporation and is provided by default with the robot control the programming pendant and robot cable The terms are designated as follows in this manual Term Description Control Robot control Industrial robot Robot Programming pendant teach box Pro...

Page 6: ... branch office 1 4 Intended use Typical applications Flange mounting tools Installation of spot welding guns Installation of arc welding equipment Installation of grippers Machining and transporting workpieces or products 1 5 Improper use Any use that deviates from the intended use shall be regarded as impermissible misuse This includes Transport of people and animals Use as ascending aid Use outs...

Page 7: ...r operating instructions Basic Information Installation and Wiring and System Setup In order to illustrate details clearly some drawings are shown with the protective covers or shields removed All protective covers and shields must be mounted before the robot is operated The drawings and figures in this manual are representative illustrations They may differ from the product delivered YEU R reserv...

Page 8: ...Stop button 1 Short Cut Main Menu JOB CONTENT 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 TEST01 TOOL CONTROL GROUP R1 S 0000 NOP SET B000 1 SET B001 0 MOVJ VJ 80 00 MOVJ VJ 80 00 DOUT OT 10 ON TIMER T 3 00 MOVJ VJ 80 00 MOVJ VJ 100 00 MOVJ VJ 100 00 MOVJ VJ 100 00 MOVJ VJ 100 00 Turn on servo power JOB EDIT DISPLAY UTILITY MOVJ VJ 0 78 S SELECT X S X L Y L Y U Z U Z R X R X B Y B ...

Page 9: ...ling or Universal Application An area must be left clear so that the operator can retreat to it in case of emergency The following inspection procedures must be performed prior to teaching the robot If problems are found correct them immediately and be sure that all other necessary measures have been performed Check for problems in robot movement Check the connectors for tight fit and all cables f...

Page 10: ...o promptly detect a warning A warning message is output as a dedicated output signal so it is recommended that you monitor it on the system side as a warning signal for the sake of safety Refer to Concurrent I O E1102000155XX01 or higher for details on the signal output XX is the language of the document Tab 1 1 Dedicated output signal 80290 SOUT 0575 COOLING FAN2 ERROR ...

Page 11: ...anufacturer Address YASKAWA ELECTRIC CORPORATION 2 1 KUROSAKISHIROISHI YAHATANISHI KU KITAKYUSHU JAPAN 1 10 Authorized representative Address YASKAWA Europe GmbH Robotics Division Yaskawastr 1 85391 Allershausen Germany ...

Page 12: ...hecking the scope of delivery The standard delivery includes the following items Fig 2 1 Scope of supply Programming pendant The present assembly instructions Robot controller Cable Robot MOTOMAN MANUAL 1 2 3 5 4 DX200 1 4 2 5 3 ...

Page 13: ...e NOTICE Please contact the local YASKAWA branch office if the serial numbers do not match the information on the delivery note S N DX200 YASAKAW DX200 Part No Power Supply Peak kVA AC 400 415 440 Average kVA Serial No Date Signature Type ERDR Robot Type Robot Order No Robot Serial No YASKAWA ELECTRIC CORPORATION 2 1 SHIROISHI KUROSAKI YAHATANISHILU KITAKYUSYU JAPAN YASKAWA Europe Robotics Divisio...

Page 14: ...exerted on the robot controller on the robot or on other components 3 1 Transporting method CAUTION Damage to persons and damage to property due to external force influences External forces must not be exerted on the robot or the motors Check that the eyebolts are securely fastened The robot weights approximately 1820 kg Use load carrying devices strong enough to withstand the weight The transport...

Page 15: ...lift Make sure that the forklift and the transportation route have sufficient bearing capacity Always take due care when transporting the robot 3 2 Shipping brackets and bolts NOTICE Before turning ON the power check to be sure that the shipping bolts and brackets are removed After removing the transport securing devices and the shipping bolts keep them at a safe place The transport securing devic...

Page 16: ...Transportation 3 16 The shipping brackets and bolts are painted yellow Fig 3 2 Position of shipping bolts Item Screw type Part A Screw M20 12 9 4 B and C Screw M10 12 9 4 C A B ...

Page 17: ...e protective measures can lead to death of people serious bodily harm or material damage Implement the following protection measures Separating protection devices Non contact protection devices Enclosures Marked areas Signs Emergency Stop button Display elements NOTICE Operator s responsibility The operator of a robot or a robot system must ensure that all specifications and requirements of the st...

Page 18: ...port surface of the robot base 0 5 mm 4 3 Installation example 1 At the first set out anchor the base plate firmly onto the floor 2 The robot base is tapped for 8 mounting holes Fix the robot base with the screws M20 Strength category 12 9 Minimum length 80 mm 3 Next fix the robot base to the base plate Tighten the hexagon head bolts and anchor bolts securely so that they will not work loose durin...

Page 19: ... of the robot As a rough standard if there is a concrete thickness floor of 200 mm or more the robot base can be fixed directly to the floor with anchor bolts Before mounting the robot however check that the floor is level and that all cracks etc are repaired A floor with a thickness of less than 200 mm does not have sufficient support for an installation Create a sufficient fixation which can wit...

Page 20: ...s and moments of the robot Direction of move ment Horizontal Vertical Force FH Moment MH Force FV Torque MV Emergency stop Stop category 0 20580 N 39200 Nm 49980 N 62720 Nm Acceleration Decelera tion Stop category 1 6370 N 11760 Nm 21560 N 15680 Nm MV MH FH FV ...

Page 21: ...rds and wiring regulations for earthing The cable cross section must be 6 mm or more For information on connecting the earthing cable directly see Fig 5 1 Earthing connection NOTICE Note on the earthing connection Never use the earthing cable together with an earthing cable of for example A different electrical consumer A different motor driven consumer Welding devices etc If the earthing cable is...

Page 22: ...the robot base and on the robot controller see the following chapter on robot connection and robot controller connection Fig 5 3 Robot cable Robot control side Encoder cable 1BC Robot side Power cable 2BC DX200 YASAKAW DX200 Part No Power Supply Peak kVA AC 400 415 440 Average kVA Serial No Date Signature Type ERDR Robot Type Robot Order No Robot Serial No YASKAWA ELECTRIC CORPORATION 2 1 SHIROISH...

Page 23: ...wer cable 2BC 2 Connect the encoder cable 1BC to the connector plate of the robot 3 Connect the power cable 2BC to the connector plate of the robot Make sure that you hear each locking clip snap into place clicking sound Fig 5 4 Connector plate of the robot S1 2BC 1BC FB C D E A B ...

Page 24: ... order 1 Connect the encoder cable 1BC X11 at connection X 1 to the robot controller 2 Connect the power cable 2BC X21 at connection X 2 to the robot controller Make sure that you hear the locking clips snap into place clicking sound Fig 5 5 Connection of the robot controller X 11 X 21 X 1 X 2 ...

Page 25: ...1 PROGRAMMING PENDANT PROPERLY CHECK ALL THE DOOR LOCKS NJ3005 1 kVA kVA ERDR Average Peak NJ3053 1 Kammerfeldstr 1 D 85391 Allershausen 2 1 Kurosaki Shiroishi Yahatanishi Ku Kitakyushu City Fukuoka 806 0004 Japan YASKAWA Electric corporation Robot Serial No Robot Order No Robot Type Type Date Signature Serial No AC 400 415 440 V Power Supply Part No Motoman DX100 with power ON WARNING Do not open...

Page 26: ...ist yaw pitch T axis wrist twist 360 360 Protection class IP Main axes 54 Wrist axis 67 Maximum speed S axis 1 57 rad s 90 s L axis 1 75 rad s 100 s U axis 1 92 rad s 110 s R axis B axis T axis 3 40 rad s 195 s Admissible moment Nm 3 3 See the following diagram Moment of arm rating in section 7 for further information on the permissible moment of inertia R axis B axis T axis Permissible moment of ...

Page 27: ...g 6 2 Robot base dimensions Upper arm U arm Rotating head of S axis Wrist flange Robot base Lower arm L arm 2 holes Ø 20 H7 Hole Ø 12 H7 8 mounting holes Ø 22 All dimensions in mm T U L S S L U T 1 3 2 4 5 1 4 2 5 3 540 540 710 350 879 519 640 640 360 0 1 320 0 1 360 0 1 220 0 1 220 0 1 300 0 1 320 0 1 1 2 3 1 3 2 ...

Page 28: ...sions and defined work area P point Working area defined with point P T point All dimensions in mm R 6 9 7 1300 1300 1600 1600 R3 159 R1037 0 270 1250 880 1037 3159 0 1400 250 300 1 5 5 2529 R1 124 2776 614 2162 2363 2624 45 9 0 120 T U L S 820 2204 3 1 2 625 616 1241 1 3 2 ...

Page 29: ... may be changed depending on the type of application If any modification is necessary please contact the local YASKAWA branch office The mechanical stop can only be adjusted in 60 steps Item Specifications S axis working range 180 standard 165 150 135 120 105 90 75 60 45 30 15 ...

Page 30: ...e Working Area To change the working area of S axis the following components are required see the following figure Fig 6 4 Components of the S axis limit 3 screws M20 x 70 strength category 12 9 and 3 x M20 washers Pin Limit stop HW0307574 1 1 2 3 1 3 2 ...

Page 31: ...ing table 6 4 3 Adjusting the S Axis Pulse Limit Check whether both sides are stabilized with screws as shown in the following diagram Fig 6 5 Mounted correctly with regard to the force limitation of the unit When adjusting the setting angle of the mechanical S axis limit the machine must be symmetrical to the illustrations see in chapter 6 4 3 Adjusting the S Axis Pulse Limit on page 32 As descri...

Page 32: ...both the pulse limit and the angle of the mechanical S axis limit Fig 6 6 Adjustable angle for the S axis limit Degree 15 30 45 60 75 90 Number of pulses 0 34092 68183 102275 136367 170458 204550 Degree 120 135 150 165 180 Number of pulses 238642 272733 306825 340917 375008 409100 The angle in plus direction adjustable angle The angle in minus direction non adjustable angle 180 165 150 135 120 105...

Page 33: ...limitation The limit can be used on both sides Screw 2 1 2 1 180 165 1 2 1 2 150 135 1 2 1 2 120 105 1 2 1 2 90 75 1 2 1 2 60 45 1 2 2 1 30 15 165 2 1 150 165 150 2 1 135 120 135 2 1 120 1 2 105 90 105 2 1 9 0 2 1 75 60 7 5 2 1 2 1 45 30 2 1 2 1 1 2 0 1 2 15 1 2 ...

Page 34: ...n times may differ due to internal and external influence on the braking torque According to the mode robot application and number of triggered safety stops with stop category 0 a different brake wear may occur We recommend that the coastdown path be checked once a year Fig 6 7 Main axes at 100 66 and 33 deflection In Fig 6 7 Main axes at 100 66 and 33 deflection the S L and U axes are shown at 33...

Page 35: ...n 33 deflection deg deg s deg s sec 0 2 0 4 0 6 0 8 1 0 0 30 60 90 120 0 5 10 15 20 25 30 35 0 30 60 90 120 deg deg s deg s sec 0 0 0 1 0 2 0 3 0 4 0 5 0 30 60 90 120 0 5 10 15 20 25 30 35 0 30 60 90 120 deg deg s deg s sec 0 0 0 1 0 2 0 3 0 4 0 5 0 30 60 90 120 0 5 10 15 20 25 30 35 0 30 60 90 120 ...

Page 36: ...Technical data 6 36 6 5 1 2 Stop position L axis 100 deflection deg deg s deg s sec 0 5 10 15 20 25 30 35 0 30 60 90 120 0 0 0 1 0 2 0 3 0 4 0 5 0 30 60 90 120 ...

Page 37: ...Technical data 6 37 6 5 1 3 Stop position U axis 100 deflection deg deg s deg s sec 0 5 10 15 20 25 30 35 0 30 60 90 120 0 0 0 1 0 2 0 3 0 4 0 5 0 30 60 90 120 ...

Page 38: ...ion 6 5 2 3 Stop position U axis 100 deflection deg deg s deg s sec 0 0 0 2 0 4 0 6 0 8 1 0 0 30 60 90 120 0 10 20 30 40 50 0 30 60 90 120 deg deg s deg s sec 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 30 60 90 120 0 10 20 30 40 50 0 30 60 90 120 deg deg s deg s sec 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 30 60 90 120 0 10 20 30 40 50 0 30 60 90 120 ...

Page 39: ...NOTICE Before mounting a tool remove anticorrosive coating on the flange Thinner or light fuel oil are the most suitable for this purpose Fig 7 1 Wrist flange 7 2 Maximum load of the S axis For peripheral devices of specific applications additional mounting options are provided on the robot 7 3 Optimal robot performance To achieve optimal robot performance the maximum load of the S axis must never...

Page 40: ...g conditions should be observed to attach or install peripheral equipment Tab 7 1 Installation Conditions Fig 7 3 Installing peripheral equipment mounts P point B axes rotation center line R T axes rotation center line All dimensions in mm View A 6 threaded holes M6 x 15 Section B B 2 threaded holes M6 x 15 All dimensions in mm 200 800 600 400 200 400 600 800 1000 1 3 2 1000 200 400 600 800 1000 L...

Page 41: ...Allowable load for wrist axis and wrist flange 7 41 Tab 7 1 Installation Conditions Application Notice Wiring and valve load Up to 300 kg for attaching load mass including wrist load ...

Page 42: ...axis varies and depends on the permissible torque Contact your YASKAWA branch office in a timely manner if you have questions regarding the calculation of the load or centroidal distance Example In the case of the YASKAWA HP20D robot for example the permissible moment of inertial for the T axis amounts to 0 25 kgm at a permissible torque of 19 6 Nm and to 0 75 kgm at a permissible torque of 0 1 Nm...

Page 43: ...se must not exceed 600 kPA the inner diameter of the air hose is Ø 7 5 Fig 8 1 Plug for internal cables and compressed air routing Air inlet A B C D and E with cap Connector for the internal cable bushing on the stand Power input module View A There is a connecting plug for internal cable ducting in the case Air inlet A B C D and E with cap Tube for fieldbus cable Ø12 on casing View B Tube for fie...

Page 44: ... pipe for the field bus cable inner diameter 12 mm 12 mm will be connected over a connection inthere the cable is lead Step 2 Remove the connection from the field bus cable pipe Pull the field bus cable fastened at the cable is until it gains the connection Step 4 Separate the cable from field bus cable by cutting off Step 5 Remove the connection fasten cable at the field bus cable and then lead i...

Page 45: ...2 A sufficient clearance must be maintained between the protective cover and the internal cables etc The ratio of the total cross section the internal cables and the protective cover may not exceed 30 The pins used on the connectors 23 wires 23 x 0 50 mm and 5 pneumatic lines are connected to the stand and arm with individual wires In the standard specification pins 7 and 8 are connected as follow...

Page 46: ... BAT OBT No 6CN OBAT2 PG5V2 BAT2 PG0V2 2 3 4 1 L No 2CN 1 9 6 5 4 2 0V BAT OBT 5V L AXIS PG DATA 3 DATA 3 2 OBAT3 PG0V3 PG5V3 4 3 BAT3 No 7CN 1 U OBT 5 4 9 10 BAT 5V 0V OBT FG3 No 3CN 1 2 6 BAT PG U AXIS DATA 6 DATA 6 OBAT6 PG0V6 PG5V6 BAT6 No 8CN 2 3 4 1 T No 4CN 5 4 9 10 1 2 6 OBT FG6 5V BAT 0V OBT BAT T AXIS PG CN1 1 SPG 1 CN1 2 SPG 1 P CN1 1 CN1 2 SPG 1 SPG 1 CN1 3 FG1 CN1 3 FG1 CN1 8 FG2 CN1 ...

Page 47: ...D 3 D 4 D 5 D 6 D 2 D 1 MU2 MU2 MV2 MV2 MW2 MW2 ME2 ME2 BA1 BA2 F 8 F 7 F 2 F 1 F 5 F 6 F 3 B 5 B 4 F 4 E MU1 MV1 MU1 MW1 MW1 MV1 ME1 ME1 2BC 8X5 E 8 E 7 E 2 E 5 E 6 E 1 E 4 E 3 C D B A No 15CN MU3 MW3 ME3 MV3 C D B No 13CN A MW6 ME6 MV6 MU6 SM T Achse SM U Achse MU2 ME2 MW2 MV2 D C B No 11CN A MV1 MW1 MU1 ME1 BB1 BA1 B C D No 9CN A 2 1 SM L Achse SM YB S Achse E B 3 C 4 C 6 C 2 C 5 A 3 A 6 B 10 B...

Page 48: ...king maintenance and inspection measures Turn OFF the main power supply Put up the required warning sign e g Do not turn the power on Install a switch on guard as prescribed If you have any questions regarding disassembly or repair please contact the local YASKAWA branch office NOTICE Home position data is lost Before removing the connector of the encoder cable to perform maintenance or inspection...

Page 49: ...Y UTILITY Main Menu ShortCut CONTROL POWER TIME 1998 07 06 10 00 2385 42 02 SERVO POWER TIME 1998 07 06 10 30 36000 00 00 PLAYBACK TIME 1998 10 22 11 12 2210 00 20 MOVING TIME 1998 10 22 15 30 1875 15 30 OPERATING TIME 1998 10 22 16 12 0 0 0 1 Short Cut Main Menu JOB CONTENT 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 TEST01 TOOL CONTROL GROUP R1 S 0000 NOP SET B000 1 SET B001 0 MO...

Page 50: ...robot Visual inspection Dirty working area has to be cleaned Please control the robot for damage and external cracks 4 Motors for L and U axes Visual inspection Check for grease leakage2 5 Fastening bolts of baseplate Using correspond ing tool Tighten loose screws replace if necessary 6 Power input module Manual Check for loose connectors 7 L and U axes motor connec tion Manual Check for loose plu...

Page 51: ...robot If a battery alarm appears or after the robot has been operated for 36 000 hours the battery must be replaced 13 S L U and T axes gear Grease gun Check for faults replace if necessary The grease5 has to be refilled every 5 000 hours or replaced every 9 000 hours see chapter 9 3 1 Grease replenishment exchange the main ax es on page 60 and 9 3 2 Grease replenish ment exchange the wrist axes o...

Page 52: ...KAWA branch office 3 When checking for conduction with multimeter connect the battery to BAT and OBT of connectors on the motor side for each axis Now remove the connectors of the encoders of the respective motor Failure to observe this sequence can lead to loss of home positions 4 Wire harness in Robot is to be changed at 18 000 H inspection 5 The grease and or lubricants used can be found in the...

Page 53: ...Maintenance and inspection 9 53 Fig 9 2 Inspection intervals The numbers in the above figure are equal to the numbers in the table of Inspection intervals A ...

Page 54: ... 9 4 Battery unit location top view The battery units are installed as shown in picture The location of the battery unit If battery alarm occuring in the robot controller battery pack has to be changed in the following form 4 screws M4 Stand Power input module Battery unit Circuit board S1 2BC 1BC FB C D E A B 1 3 2 1 3 2 1 2 1 2 ...

Page 55: ...he plug from circuit board 4 Connect the new battery pack to the unoccupied connector on the board Fig 9 6 Battery pack connections 5 Remove the old battery pack from the battery holder 6 Mount the new battery pack to the battery holder NOTICE The absolute encoder data will be lost Never remove old battery pack before having installed new battery pack Main power switch in switch off position Old b...

Page 56: ...rd NOTICE Make sure that no wires are pinched when you install the battery pack and the cover plate again 8 Please apply Teroson Plast sealing compound material no 143813 to thread part of screws Exchanging the battery unit iscompleted after reinstalling the cover plate on the plug plate ...

Page 57: ...Battery unit connector diagram for R B and T axes Motor Battery unit Motor power connector Plug for backup Encoder connector Encoder Warning label Motor cable Power connector Battery unit Wiring harness of the robot a Plug socket b Plug pin Motor Encoder connector b a a b OBT BAT BAT OBT 4 1 2 3 5 1 4 2 5 3 Connect battery to encoder to save the data before removing connector CAUTION OBT BAT OBT4 ...

Page 58: ...ose etc to the grease outlet If this instruction is not followed the motor will be damaged Avoid air getting into the gear Insert grease with a grease gun If an automatic lubricating pump is used the grease supply pressure must be 0 3 kPa Set the grease injection rate to a value not higher than 8 g s The limit values may not be exceeded also if a conventional grease gun is used In ceiling mounted ...

Page 59: ...queeze out the excess fat all taxes must be brought to operating temperature In a operating JOB or a special moving JOBs about 20 minutes at 100 speed 5 Wipe away excess grease with a cloth 6 Remove the lubricating nipple from the grease inlet opening and mount the plug again Before mounting the plug apply to thread part Tightening torque the set screw Designation Tightening torque Nm PT 3 8 23 PT...

Page 60: ...Figure the axes Amount of grease S axis gear Replenishment 2100 cm approx 1827 g Exchange 10400 cm approx 9048 g1 1 The grease exchange is complete when new grease appears from the exhaust port The new grease can be distinguished from the old grease by color L axis gear Replenishment 360 cm approx 313 g Exchange 1800 cm approx 1566 g1 U axis gear Replenishment 320 cm approx 278 g Exchange 1600 cm ...

Page 61: ...Maintenance and inspection 9 61 Air outlet cap Joint 80 9 0 170 1 1 2 2 2 1 2 ...

Page 62: ...t axes Figure the axes Amount of grease BT axis gear Replenishment Variable BT Achsen Getrie be Fettmenge nachfüllen not defined Exchange Variable BT Achsen Getrie be Fettmenge tauschen not defined 1 U axis cross roller bearing Replenishment 60 cm approx 54 g1 Grease outlet opening Grease inlet opening 1 2 ...

Page 63: ...ints 1 2 3 6 6 cm approx 5 g Amount of grease for joints 4 5 9 12 cm approx 10 g Amount of grease for joints 7 8 3 cm approx 2 5 g Amount of grease for joints 10 11 5 cm approx 4 5 g 10 5 1 6 2 5 2 3 6 4 6 7 9 9 3 10 10 7 8 2 4 11 10 10 3 9 9 1 7 8 2 3 10 8 1 11 11 5 2 4 A A 1BC A 4BC 2BC 3BC F E B C A ...

Page 64: ... setting the home position the position of the absolute encoder must match it Although this operation is performed prior to shipment at the factory the following cases require this operation to be performed again Change in the combination of the robot and robot controller Replacement of the motor or absolute encoder Clearing stored memory by replacement of the main CPU board weak battery pack etc ...

Page 65: ...Maintenance and inspection 9 65 9 4 1 Register all axes 1 Select ROBOT from the main menu The sub menu choices appear 2 Select HOME POSITION The HOME POSITIONING window appears ...

Page 66: ... 3 can also be performed by selecting the PAGE button In this case a selection box appears 4 Select the sub assembly to calibrate e g R1 ROBOT Select the control group for HOME POSITIONING The control group can also be selected by pressing page key 5 Select EDIT in the main menu The pull down menu appears ...

Page 67: ...d inspection 9 67 6 Select SELECT ALL AXES A confirmation dialog box is displayed 7 Select YES Displayed position data of all axes are registered as home position When NO is selected the registration will be canceled ...

Page 68: ... be calibrated e g R1 ROBOT Perform steps 3 and 4 as described in section 9 4 1 Register all axes to select the desired control group 4 Move the cursor to the axis you want to register and select it A confirmation dialog box appears 5 Select YES The displayed position data of the selected axis is registered as the zero position If you select NO registration is aborted ...

Page 69: ...n menu The sub menu choices appear 2 Select HOME POSITION 3 select the sub assembly components to be calibrated Carry out steps 3 and 4 as described in section 9 4 1 Register all axes on page 65 to select the desired control group 4 Select the absolute data to be registered 5 Enter the absolute data using the numeric keys 6 Select ENTER The absolute encoder data is changed ...

Page 70: ...sub menu choices appear 2 Select HOME POSITION Carry out steps 3 and 4 as described in section 9 4 1 Register all axes on page 65 to select the desired control group 3 Select DATA from the main menu The pull down menu appears 4 Select CLEAR ALL DATA A confirmation dialog box appears 5 Select YES All absolute data will be deleted When NO is selected the registration will be canceled ...

Page 71: ...the pulse generating system The robot was moved after the power supply was turned OFF If the alarm OUTSIDE THE RANGE ABSOLUTE DATA appears automatic mode is not possible The home position must be checked If the OUT OF RANGE ABSO DA TA alarm occurs Compare second home position check point with current position pulses Alarm reset The alarm occurs again Switch the servo power on Correct the faulty ax...

Page 72: ...n 9 5 2 Procedure for the second home position setting on page 73 Alarm message If the alarm occurs again the error may be in the PG system Check the pulse generating system Once you have set the faulty axis set the zero position of the axis and then check the position again NOTICE If you set the zero position simultaneously for all axes automatic mode is possible without a position check However ...

Page 73: ... absolute data Use the following steps to set the specified point NOTICE If 2 or more Robots or stations are controlled by one controller the second home position must be set for each robot or station 1 Select ROBOT from the main menu The sub menu choices appear 2 Select SECOND HOME POS The SECOND HOME POS window appears Message is spoken Available to move to and modify specified point ...

Page 74: ...ction 1 7 Safety on page 8 WARNING Death or injury because of danger of crushing Irregularities in the PG system may lead to an alarm and the robot may perform unexpected movements If the OUT OF RANGE ABSO DATA alarm occurs Reset the alarm the SERVO power ON Then confirm the second home position After the confirmation if the PG system is found to be the cause of the alarm perform the necessary ope...

Page 75: ...to you intend to specify second home position 4 Press FWD TCP moves to the second home position The robot moving speed is set as selected manual speed 5 Select DATA in the menu 6 Select CONFIRM POSITION A message Home position checked appears Pulse data of the second home position and current pulse data should be compared Automatic mode can be done if compared error is in allowed range If the erro...

Page 76: ...E146745 20 kg A Sealing compound Teroson Plast 143813 200 ml A Battery unit Robot 128708 1 1 A Battery unit Control 155543 1 1 B S axis gear HW0281280 A E112628 1 1 B Pinion HW0307565 3 E139282 1 1 B L and U axes gear HW0388209 A 144077 1 2 B Pinion for L and U axes HW9482126 A 112632 1 2 B Bearing for L and U axes HW9481343 A 111887 1 2 B Pinion for L and U axes HW9482306 F 151172 1 2 B T axis ge...

Page 77: ...029 1031 1032 1039 1001 1002 1078 1011 1012 1013 1079 1077 1021 1022 1023 1024 1025 1037 1038 1040 1017 1014 1015 1003 1004 1035 1030 1033 1026 1058 1059 1060 1061 1058 1062 1061 1059 1063 1048 1049 1050 1048 1051 1052 1053 1044 1045 1041 1042 1043 1066 1046 1047 1054 1055 1056 1057 1064 1065 1067 1069 1070 1072 1071 1080 1082 1081 1068 1076 1075 1036 1027 1019 1020 1034 ...

Page 78: ...H 8 Washer 1 1026 HW0407007 1 Pin 1 1027 HW0403903 1 Metal sheet 1 1028 M20 x 70 12 9 Screw 3 1029 M20 Washer 3 1030 HW0402102 1 Stop 1 1031 M8 x 40 Screw 1 1032 2H 8 Washer 1 1033 HW9404486 1 Shaft 1 1034 M5 x 16 Screw 8 1035 S180 O ring 1 1036 MSTM6 20 Pin 2 1037 M12 x 40 Screw 4 1038 2H 12 Washer 4 1039 HW0307574 1 Stop 1 1040 HW0101152 1 Housing 1 1041 AR175 Ring 1 1042 WR140 Ring 1 1043 6828Z...

Page 79: ...r 2 1061 6207ZZ Bearing 2 1062 HW0307656 1 Pinion 1 1063 HW9405051 1 Cover 1 1064 2H 5 Washer 7 1065 M5 x 16 Screw 7 1066 M12 x 20 Screw 1 1067 PT3 8 Set screw 1 1068 HW0314644 A Cover 1 1069 M8 x 25 Screw 2 1070 2H 8 Washer 2 1071 HW0471083 A Cooling fan 1 1072 A 33C Fan cover 1 1075 TA1 S10 Terminal 4 1076 M5X10 Screw 4 1077 HW0308464 1 Flange 1 1078 TC8511013 Oil seal 1 1079 HW0308465 1 Shaft 1...

Page 80: ...81 2081 2068 2068 2052 2052 2048 2072 2053 2048 2002 2054 2029 2030 2033 2035 2046 2070 2083 2047 2042 2036 2075 2082 2036 2029 2030 2045 2045 2045 2067 2076 2077 2078 2055 2057 2003 2008 2076 2077 2031 2035 2058 2043 2056 2041 2041 2039 2040 2045 5004 2071 2073 2074 2045 2059 2085 2086 2025 2086 2025 ...

Page 81: ...ller bearing 1 2013 1011 2020 2008 2010 2019 2001 2011 2040 2032 2035 2037 2007 2012 2021 2014 2015 2016 2009 2028 2039 2040 2031 2080 2035 2026 2030 2022 2004 2023 2045 2002 2013 2018 2018 2017 2087 2014 2015 2016 2021 2006 2022 2001 2005 2034 2035 2031 2035 2038 2040 2027 2030 2019 2087 2094 2045 2045 2045 2045 2094 2045 2086 2045 2025 2045 2095 2095 2045 2092 2093 2092 2093 ...

Page 82: ...20 GS310 O ring 1 2021 Y507212 5 Oil seal 2 2022 VB 265 280 7 Oil seal 2 2023 M8 x 25 Screw 12 2025 2H 8 Washer 20 2026 M10 x 60 Screw 18 2027 M10 x 50 Screw 18 2028 M10 x 45 Screw 1 2029 M10 x 25 Screw 2 2030 2H 10 Washer 38 2031 M12 x 75 Screw 33 2032 M12 x 55 Screw 4 2033 M12 x 50 Screw 12 2034 M12 x 40 Screw 4 2035 2H 12 Washer 53 2036 M8X25 Screw 8 2037 M16X65 Screw 6 2038 M16X60 Screw 6 2039...

Page 83: ...17A4 Oil seal 1 2071 VB60787 Oil seal 1 2072 WR60 Circlip 1 2073 VB75956 Oil seal 1 2074 AR 85 Retaining ring 1 2075 NA6912 Bearing 1 2076 AG3512E1 Oil seal 2 2077 HR32011XJ Bearing 2 2078 G85 O ring 1 2079 KE901107 Oil seal 2 2080 M10 x 45 Screw 9 2081 M10 x 50 Screw 18 2082 G75 O ring 1 2083 HW0484003 A Bearing 1 2085 2H 6 Washer 1 2086 2H 10 Washer 27 2087 HW0408806 2 Washer 2 2092 TSH6 01M Lin...

Page 84: ...ew 1 3034 3037 3030 3032 3022 3009 3023 3005 3001 3006 3006 3007 3008 3010 3010 3011 3012 3013 3014 3015 3020 3021 3028 3031 3041 3034 3036 3038 3039 3016 3017 3018 3002 3003 3004 3005 3001 3004 3017 3018 3023 3023 3023 3030 3032 3032 3030 3032 3024 3033 3027 3024 3033 3033 3022 3022 3023 3030 3032 3035 3019 3021 3009 2002 2054 3009 3030 3032 3029 3029 3028 3032 3031 3034 3005 3005 3005 3005 3005 ...

Page 85: ...Screw 1 3021 2H 12 Washer 11 3022 HW0406922 1 Cover 3 3023 HW0406923 1 Washer 5 3024 HW0307641 1 Shaft 2 3027 HW0484003 A Bearing 3 3028 M10 x 30 Screw 8 3029 2H 10 Washer 8 3030 M10 x 25 Screw 5 3031 M10 x 50 Screw 8 3032 2H 10 Washer 13 3033 AG3217A4 Oil seal 3 3034 G75 O ring 3 3035 MSTH6 10 Pin 2 3036 HW0200686 1 Joint 1 3037 HW0308095 1 Joint 1 3038 HW0101147 1 Housing 1 3039 HW0101148 1 U ar...

Page 86: ...39 4025 4021 4016 4015 4015 4010 4014 4014 4013 4013 4017 4018 4017 4011 4012 4019 4020 4019 4005 4020 4004 4004 4008 4009 4003 4007 4024 4024 4006 4023 4022 4024 4024 4018 3037 4002 4026 4040 4030 4031 4055 4054 4051 4050 4043 4042 4041 4035 4049 4027 4039 4053 4036 4028 4034 4052 4001 4045 4029 4037 4032 4045 4044 4046 4038 4033 4038 4024 4024 4049 4056 4048 4047 ...

Page 87: ... 10 Washer 2 4021 M8 x 25 Screw 3 4022 M8 x 30 Screw 3 4023 M6 x 20 Screw 3 4024 PT1 8 Set screw 7 4025 LP M5 Set screw 1 4026 HW0314598 1 Pipe 1 4027 HW0314599 1 Pinion 1 4028 HW0314600 1 Pinion 1 4029 HW0314601 1 Housing 1 4030 HW0314602 1 Flange A 1 4031 HW0314603 1 Flange B 1 4032 HW0414320 1 Nut 1 4033 HW0414321 1 Housing 1 4034 HW0412116 1 Shaft 1 4035 HW0403139 1 Data 1 4036 R10 27 Washer 1...

Page 88: ...4 4047 M10 x 20 Screw 8 4048 2H 10 Washer 8 4049 M4 X 10 Screw 8 4050 M8 x 80 Screw 30 4051 2H 8 Washer 30 4052 M6X20 Screw 1 4053 2H 6 Washer 1 4054 M10X20 Screw 9 4055 2H 10 Washer 9 4056 MSTH8 20 Pin 1 3037 HW0308095 1 Joint 1 3039 HW0101148 1 U arm 1 No DWG no Description Pcs ...

Page 89: ...o DWG no Description Pcs 5001 HW0481740 A Spring 1 5002 HW0481741 A Spring 1 5003 SOB607440 Sleeve 2 5004 HW0100477 1 Housing 1 5005 HW0306033 1 Flange 1 5001 5002 5017 5003 5004 5005 5006 5007 5008 5009 5010 5011 5012 5012 5013 5014 5015 5016 5003 5018 5019 5020 ...

Page 90: ...581 1 Pipe 1 5009 HW9405057 1 Fork head 1 5010 FD3187A0 Dust seal 1 5011 EZ2228B0 Cap 1 5012 IRTW 75 Stop 2 5013 M6 x 8 Screw 2 5014 PT1 8 Set screw 3 5015 M10 x 40 Screw 8 5016 2H 10 Washer 8 5017 HW0481742 A Spring 1 5018 M8 x 16 Screw 3 5019 2H 8 Washer 3 5020 M5 x 10 Screw 2 No DWG no Description Pcs ...

Page 91: ...Parts lists 11 91 ...

Page 92: ...YASKAWA Headquarter ...

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